Casement Windows for a Victorian Bungalow in Seminole Heights

There's a lot to building a window, so I put on a few pictures to give you an idea of what's involved in putting some casement windows together.

First we start with the sash, which we make in my shop. We have specialized tools and set ups that simplify putting them together. At this point, it takes approximately one hour per sash. Depending on the work load, we'll put the glass in ourselves or outsource that step to Acme Glass on Nebraska and Osbourne. Windows are primed before glazing the glass in.

A casement window operates basically like a miniature door. It has hinges, sits in a frame and locks. Mine have weatherstripping all around the same way a door does and can be weather tight.

When I am making a set of windows like I've done for Eric Krause's Victorian bungalow, I make a special hinge jig specific for the windows at hand. The jig allows me to get the hinge spacing exactly the same on every window. My clients like such conformity.

Shown at the left is the jig attached to the window sash. I attach it firmly in place with small screws and then use the jig as a template to rout out the mortises for the hinges. I do them all at once so they all come out the same.

Once all the sash are routed for the hinges, I use the same jig to rout the cases for the hinges. It's really a simple process. The hardest part is getting set up accurately, which can take a little bit. But once your set up, you can pump out a lot of production in a minimum of time.

After everything is routed, I install the hinges on both the case and the sash then put them together. If I've done everything right I get to stand back and smile, admiring them before I put them in.